Automobile door structure



Nov. 24, 1953 A. L. NELSON AUTOMOBILE DOOR STRUCTURE 3 Sheets-Shea?l l Filed Deo. 28, 1950 I INVENTORQ 406467 Z. /1/1/:04/ BY ff' ,1 )ra/Jv Nov. 24, 1953 A. L. NELSON AUTOMOBILE DooR STRUCTURE 5 Sheets-Sheet 2 Filed Dec?.v 28, 1950 INVENToR. 4a/sas? /l/fzSO/V Nov. 24, 1953 Aj 1 NELSON AUTOMOBILE DOOR STRUCTURE 3 Sheets-Shee. 5

Filed DeO. 28, 1950 JNVENTOR. ,406067 Z. /t/zso/V Patented Nov. 24, 1953 AUTOMOBILE DOOR STRUCTURE August L. Nelson, Grand Rapids, Mich., assignor to Hayes Manufacturing Corporation, Grand Rapids, Mich.,

a corporation of Michigan Application December 28, 1950, Serial No. 203,080

2 Claims.

This invention relates generally to doors, and refers more particularly to improvements in sheet metal door` structure.

VAlthough it will be apparent from the following description that many of the features of this invention are applicable to the manufacture of doors for various purposes, nevertheless, the invention finds particular utility when employed in the production of vehicle body doors.

It is an accepted fact that Vehicle body doors must possess exceptional rigidity in order to withstand the severe stresses imparted to the doors in practically all directions during use of the vehicle. In the past reasonably satisfactory strength characteristics were obtained by forming the door with separate inner and outer panels secured together by a frame structure interposed between the panels. This construction, however,

embodies a'relatively large number of parts whichl not only increase the weight of the door, but in addition, are costly to manufacture and assemble.

With the above in view, it is an object of this invention to greatly simplify the door structure and at the same time provide a door assembly possessing the requisite strength characteristics. In accordance with this invention the door structure is simplified by providing a one-piece sheet metal panel having the marginal edge portions turned laterally and shaped to form the top, bot.;`

tom and side stiffening rails. These rails ,being integral with the panel eliminate the complicated, time-consurning assembly operationsrequired in the past where separate framing was used to stiffen the panel and also eliminate the necessity of separately forming the frame members.

Also in accordance with this invention the inner panel employed in the past is replaced by an accessory supporting plate, which is only a fraction of the size of the usual inner door panel, and is secured at opposite ends to the side rails or inturned flanges at opposite sides of the outer door panel. Thus a saving in material is not only eiected but the overall weight of the door is reduced. Also repair of the outer door panel in the event the same should become damaged is simplified.

It is a further object, of this invention to provide a door structure of the above general type having a window opening in the upper portion.

The top of the window opening is defined by the header rail on the panel and opposite sides of the opening are defined by the upper portions of the side rails on the panel. A filler strip extends along the top and sides of the window opening, and opposite edges of the strip are respectively secured to inturned flanges on the railsV and adjacent portions of the door panel. The filler stripprovides an anchorage for a garnish molding frame, and has a part which coactswith the frame to provide a glass receiving channel. it is a further object of this invention to provide a door assembly embodying the above features and having the several parts capable of being formed by relatively simple stamping operations requiring a minimum number of tools.

The foregoing as Well as other objects will be made more apparent as this description proceeds, especially when considered in connection with the accompanying drawings, wherein:

Figure l is an elevational view of side of a vehicle body door assembly;

Figure n 2 is an edge elevational view of the door shown in Figure 1;

Figures 3 to 1l inclusive are respectively cross sectional views taken on the lines 3 3, 4 4, 5 5, 5 6, 1 1, 8 8, 9 9, I0 l0 and H II of Figure l;

Figure 12 is a cross sectional'view through the top of the door assembly showing the garnish molding frame and window; and

Figure Y13 is a fragmentary elevational view of a modified corner construction for the door..

The door structure selected for the purpose of illustrating this invention is of the type employed on vehicle bodies, although it will .be apparent from the following description that many of the features of the invention may be incorporated in the manufacture 'of different types of doors, such for example, as those employed in connecthe inner tion with refrigerator cabinets, aircraft and cooking ranges.

With the above in view, reference is made more particularly to the drawings, wherein the numeralA I0 designates a vehicle body door assembly having a main panel II preferably formed of sheet metal and being of a design which lends itself to manufacture on a volume production basis by the use of a few relatively simple stamping operations. In the present instance the panel II constitutes the outer panel of the door assembly I0, and is provided with a window opening I2 in the upper portion thereof. The usual glass window I3 is provided for closing the opening I2, and

provision is made for supporting the window on the panel to enable sliding movement of the window into and out of the opening I2. y

The marginal edge portions of the panell I are turned laterally inwardly with respect to the panel to provide a flange I4 which forms the side A edges of the door I 0, and the inner portion of the flange I4 is turned laterally inwardly with respect to the flange to provide a flange I5. The flange I5 coacts with the panel I I and flange I4 to form inwardly opening generally channel-shaped top, bottom and side rails I6, II and lrespectively on the panel I I. As indicated in the several cross sectional views of the drawings, the free end of the flange I.5. may be turned laterally outwardly to form. a stiflening flange I9. The rails or flanges noted above extend substantially continuously around the perimeter of the panel II, andI impart sufcient strength to the panel I I to render the provision of separate pillars or frame' members unnecessary.

It will further be noted from the various cross sectional views of the drawings that the edge nange I4 is drawn inwardly with respect to the. side edge of the door to provide an' inwardly opening channel-shaped section immediately adi-a cent the panel II. The inwardly opening channel-shaped section. 20 extends continuously around the perimeter of. the door panel II,. and the. inner wall 2I of the section forms a. door stop.

A`s shown in Figures 4,. 7 and 9i of' the drawings, an accessory plate 22 in the form of a sheet metal stamping is secured to the door assembly with the top edge extending along the bottom of the win.- dow opening I2. The ends of the plate are respectively secured to the flange I5 at opposite sides. of the door panel Il, and the portions 23 of the flanges I5 engaged by the plate 22 are ernbossed. laterally outwardly sufliciently to locate the inner surface of the plate 22 in a common plane with the corresponding surface of the 'ange I5`. The bottom edge ofthe plate 22 is turned outwardly to form a stiffening flange 24 and the top edge of the plate 22 is turned inwardly and. downwardly to form a downwardly opening channel-shaped ledge 25 at the inner side of the window opening I2, as shown in Figure 7 oi' the drawings. It will also be observed from Figure 7 of the drawings that the. portion` of the panel I'I at the bottom of the window opening I 2 is turned inwardly and downwardly to form a channel-shaped ledge 26 at the outer side of the window opening I2. The ledge 2.6 is spaced at a somewhat higher elevation than the ledge 25, and the downwardly extending ilangesof the ledges are spaced from each other suinciently to permit free passage of the window I3 therebetween.

The size of the plate 22 is sufficient only to adequately support the various door accessories including the window regulator mechanism and` latch construction. As shown in Figure 1 of the drawings, the bottom edge of the plate is spaced a considerable distance above the bottom of the door I3, and if desired a reinforcement in the form of a channel-shaped strap 2T may be provided for connecting the bottom rail portion II of the door to the plate 2'2 intermediate the ends of' the latter. The outer panel. II may further be strengthened by'a gusset plate 28 ofA triangular configuration and secured to the lower front.

corner of the panel. In. practice the flange I5 at'thelower front corner of the panel is. embossed laterally outwardly to form a seat for the gusset cesses 29. The recesses 29 are for the purpose of receiving hinge straps designated generally in Figure 9 by the numeral 30, and constituting part of the hinge assembly for mounting the door. In order to strengthen the front edge of the door panel II on which the hinges are attached, an inwardly opening channel-shaped reinforcing member. 3I. isl provided.. The reinforcing member 3I extends from a position adjacent the bottom of the door panel II to a position above the top recess 29 and the base of the member 3l is welded or secured to the inner side of the flange I4. Referring again to Figure 9, it will be noted that the innerI nangev 32 of the member 3I em- 1 braces the flange I5 on the panel, and the Abase of the member is embossed laterally inwardly to provide recesses 33 in positions to respectively receive the embossed portions of the adjacent flange T41.. Thus it will be seen that the edge portion of the door on which the hinges are attaohed` is reinforced to, provide a strong and rigid construction..

Referring now to Figures@ 6,. and. 10-I it will be noted that the portion of ther outer door panel I I extending along the top and sides of the win-- dow opening I2 is turned laterally inwardly to provide a flange 34 andthe free edge of the ange. 34 is turned inwardly to form a flange. 35. The

flange 35 is spaced laterally from the flange I5 and a strip 33 is positioned between the. flanges I5 and 35. The strip 3E extends along the top and sides of the. window opening I2 in the outer panel II, and is welded or otherwise permanently secured to the panel II. The strip 3-6 may be fashioned from a single strip of sheet. metal and bent to substantially inverted. U-shaped configuration or may be formed of a plurality of sections as indicated in Figure 1 of thedrawings. In either case the outer marginal edge: of the strip is bent laterally inwardly to form ar flange 31 which is. welded or otherwise permanently secured to the inner side of the flange 35. The inner edge portion of the strip 36- is drawn laterally outwardly to provide an inwardly opening channel 38,. land the inner flange 39 of the channel is turned laterally outwardly to form a ange 40. The flange 39 is welded against the outer surface of the ange l5, and the flangey 40 is welded against. the adjacent surface of theY outturned ange I9 on the panel II.. The part 4I of the strip at the outer side. of the channel 38 is fashioned to provide a seat. for engagement with the window [3 as. shown particularly in Figure. 12 of. the drawings. It will also be noted from Figure 12. that a. garnish molding frame 42 extends around the portion of the strip 36. at` the inner side of the window I3, and cooperates with the seat 4I to form a channel for receiving the window I3. The garnish molding frame is removably secured in place by screws 43 which are secured to the strip 35.

It follows from the above that the strip 36 forms with the. adjacent portion of the outer panel. II a box type construction which is extremely strong and is capable of withstanding high bending or twisting stresses that may be imparted tothe door. It will further be noted that. by forming the outer door panel II, side, 'bottom and end rails of a single piece of sheet metal, the door assembly is not only greatly simplified, but in. addition, renders it possible to eliminate numerous assembly operations heretofore required in the manufacture of door structures wherein a separate frame is provided for supporting the outer door paneL In addition it will be seen that the shape of the various parts of the outer panel is such as to enable this panel to be formed with relatively few simple stamping operations.

In Figure 13 of the drawings a modified corner construction for the door is shown. This corner construction may be employed at the corners A, B and C of the door shown in Figure 1, if desired. It will be noted that the corner shown in Figure 13 diiers from the corners A, B and C in that the outer edge 50 intersects the bototm edge 5I at substantially right angles. In order to accomplish this result adjacent marginal rails of the door are notched at their juncture, and the resulting open joint is closed by welding or by covering the joint with a suitable reinforcement (not shown). The joint is indicated in Figure 13 by the numeral 52, and is not visible from the outer side of the door.

What I claim as my invention is:

l. An automobile door comprising a unitary main panel having a window opening in the upper part thereof, and having peripheral flanges extending' completely around said panel, said flanges comprising a first flange extending generally at right angles to the adjacent portions of said panel, a second ange extending inwardly of the edge of the door from the edge of said first flange, said second flange 'being generally parallel to and spaced from the adjacent portions of Said panel, said second flange constituting a door stop and said drst iiange constituting a stiiening flange therefor, a third flange extending outwardly of the panel from the inner edge of said second flange, a fourth flange extending inwardly of the edge of the door from the edge of said third flange, a plate extending across said main panel directly below the window opening therein, the ends of said plate being secured to said fourth ange at opposite sides of said main panel, the upper edge of said plate being spaced from the portion of said main panel at the bottom of the Windowpopening therein to provide for passage of a movable window glass, and strip material connecting the portions of said fourth ange adjacent the top and sides of said window opening to the adjacent portion of the main panel.

2. An automobile door comprising a unitary main panel having a window opening in the upper part thereof, and havin-g peripheral flanges extending completely around said panel, said iianges comprising a rst ange extending generally at right angles to the adjacent portions of said panel, a second ange extending inwardly of the edge of the door from the edge of said rst flange, said second flange being generally parallel to and spaced from the adjacent portions of said panel, said second flange constituting a door stop and said first ange constituting a stiffening ange therefor, a, third flange extending' outwardly of the panel from the inner edge of said second fiange, a fourth ange extending inwardly of the edge of the door from f'- the edge of said third flange, a, plate extending across said main panel directly vbelow the window opening therein, the ends of said plate being secured to said fourth ange at opposite sides of said main panel, the lower edge of said plate being spaced substantially upwardly from the lower edge of said panel, and a brace connecting the mid-portion of said plate to the fourth ilange at the bottom of said main panel, the upper edge of said plate being spaced from the portion of said main panel at the bottom of the window opening therein to provide for passage of a movable window glass, and strip material connecting the portions of said fourth flange adjacent the top and sides of said window opening to the adjacent portion of the main panel.

AUGUST L. NELSON.

References Cited in the le of this patent UNITED STATES PATENTS 

